Dyeing synthetic tow



Sept, 29, 1959 s. 1.. ABBOTT DYEING SYNTHETIC TOW 5 Sheets-Sheet 1 Filed March 14, 1957 O O O O 0 r w fir w WW 0 a 2 2 37 r 1 Sept. 29, 1959 s, ABBOTT 2,906,593

DYEING SYNTHETIC TOW Filed March 14, 1957 3 Sheets-Sheet 2 Sept. 29, 1959 s. L. ABBOTT 2,905,593

DYEING SYNTHETIC TOW Filed March 14, 1957 3 Sheets-Sheet 3 United States Patent 2,906,593 DYEING SYNTHETIC row Samuel L. Abbott, Wilton, N.H., assignor to Abbott Machine (30., Inc., Wilton, NH, a corporation of New Hampshire Application March 14, 1957, Serial No. 645,958

6 Claims. (Cl. 8-154) A'present methodof utilizing tow of synthetic filaments such asD'ac'ron and Orlon'is to convert the tow into staple lengths and reassemble the staple length filaments into the form of top, dye the top in the form of wound dye packages, and spin the dyed material into yarn.

Woven fabrics containing Dacron or Orlon have a more satisfactory handle and appearance if the Dacron or Orlon while in the form of tow is'subjected to stretching under heat. With this procedure, the manufactured fabric is heated whichcauses it to relax and become more bulky.

However, it has not been practicable to introduce a heat stretching step into the above sequence of operations in which tow is converted to top and the top is dyed. There is no practical way of heat stretching top, and the heat stretching would accordingly need to precede the conversion of the filaments into top. However if the heat "stretching were to precede the conversion it would then also precede the dyeing and the heat of the dyeing would tend to prematurely release the stretch imparted in the heat stretching step. This stretch should not be released until after manufacture of the fabric.

Of course it would be possible in making a Dacronwool mixture to postpone combining the Dacron with the wool until after the wool top had been dyed, avoiding dyeing of the Dacron component, in which case the Dacron could be heat stretched in the tow form and retain its heat stretch in the yarn. But this expedient would result in yarn having a large proportionof undyed fibers which would only be satisfactory for certain designs of fabric.

It is not the practice of manufacturers of synthetic tow to supply tow in dyed form and even if these *manufacturers were to introduce dyed synthetic tow it would be'uneconomical for them to keep ,in stock more than a few dyed shades.

Therefore to produce staple fiber yarns containing dyed heat stretched synthetics such as Dacron or Orlon there is an important need for a way of satisfactory dyeing a batch of synthetic tow suitable for subsequent heat stretching and conversion into top. -It is the principal object of this invention to provide such a way.

This presents the problem of dyeing .the towi'n-a large enough batch so that the device which-converts the tow to staple length will not need frequent threading up. Converting devices are intended to operate with relatively large lots of tow. For instance a converting device may be fed from four ends of tow, each of 250 pound total weight. In one commonly used converting device approximately the last pounds of each lot are wasted and this waste would be prohibitively expensive if successive short lengths of tow were treated. For instance, if that device were fed simultaneously from four dye .packages of 20 pounds each, 5 pounds out of each 80 pounds would then be wasted. Apart from the waste of material, there would be considerable waste of labor in frequent threading up of the converting device. mOf even greater importance is the requirement that Patented Sept. 29, 1959 the dyeing should not disturb the tow. A typical Dacron tow weighs only about 700 grains per yard and consists of a multitude of extremely fine easily disturbed filamerits. The 'eonve'r'sion of these filaments to staple length is a delicate one and requires thatthe tow be presented in a relatively undisturbed state and if this is not done the conversion becomes defective.

Thus it is unsatisfactory to attempt to dye the tow in say 250 pound lots in dye kettles 'ofth'e raw stock type in which the material is piled upon a perforated kettle bottom through which the dye liquid is pumped. Such a dyeing procedure, though satisfactory for some materials, would not be practical for the easily disturbed tow which is to be subsequently converted.

The invention involves a new procedure whereby large batches of 'tow, for example 250 or 300 pounds or more, may be dyed in wound form so that there is little disturbance of the filaments. Following the dyeing these large batches are suitable for economical conversion to top with little Waste. In between the dyeing and converting operations the'tow can be effectively heat stretched.

The accompanying drawings are diagrammatic.

Figs. 1 and 2 are respectively a plan and an elevation illustrating preparation of a reserve for the first dye package ofa group to be prepared according to the presour invention;

Figs. 3 and 4 are respectively a'plan and an elevation illustrating winding the first dye package of the group;

Fig. 5 is a plan showing the first dye package completed;

Fig. 6 is an elevation illustrating preparation of a reserve for the second dye package;

Figs. 7 and 8 are respectively a plan and an elevation illustrating winding the second dye package;

Figs. 9 and 10 are respectively a plan and an elevation showing the second dye package completed;

Fig. 11 is an elevation illustrating preparation of the reserve for the third dye package;

Figs. 12 and 13 are respectively a plan and an elevation illustrating winding the third dye package;

Fig. 14 is a plan showing the third dye'package completed;

Fig. 15 is an elevation showing a group of four dye packages;

Fig. 16 is an elevation illustrating drawing off from the first dye package and forming the 'firstunwinding reserve;

Fig. 17 is an elevation showing drawing off from the reserve formed as in Fig. 16;

Fig. 18 is an elevation showing drawing off from the second dye package and forming the second unwinding reserve.

The invention will be explained as adapted for dyeing with the use ofan Abbott dye kettle similar to that shown in United States Patent No. 1,775,542. Such kettle may accommodate for example up to the eighteen perforated spools each holding 20 pounds of material. The winding of such large spools is facilitated if two packages are wound simultaneously, side by side, on each spool. United States Patent No. 1,797,393 may be referred to as showing such winding of two packages on one spool. Plan views of the accompanying drawings show the winding of two packages of tow simultaneously upon a given spool, but this is not essential, and in the interest of simplicity only one wound package of each spool will be referred to in explaining the invention.

In the drawings the spools 8-1, 8-2, S-3 etc. may be, for example, the perforated dye spools of the above patents.

The winding-and unwinding'apparatus is only diagrammatically shown in the drawings. Thus in Figs. 2, 4, 6, 8, 10, 11 and 13 a spool driving roll or drum 24 is shown,

3 corresponding to the spool driving roll or drum of the same number in U.S. Patent No. 1,797,393.

Open topped supply containers 25 are of a size to hold for example 300 pounds of tow, a typical batch as received from the tow manufacturer.

Open topped reserve containers 26 are of a smaller size since in a typical procedure according to this invention these reserve containers are only called upon to hold for example 5 pounds of tow.

In the initial phase of the process such a reserve, of for example 5 pounds, is drawn off from the supply container 25 and set apart. While any suitable drawingly the spool driving roll 24 can be used. In this procedure the tow T from the supply container 25 is laid over the spool driving roll 24 and an empty spool placed in position to be driven by the roll. Rotation of the roll 24 then carries the tow through the nip between the roll 24 and the barrel of the spool, and from this nip the tow passes vertically down into the reserve container 26 as best shown in Fig. 2. The roll 24 is driven through off apparatus may he used for this purpose, advantageous- 4 an appropriate number of revolutions to deliver 5 pounds reserve container and the tow extending from the supply container are doubled, this double thickness is inserted in an open top traversing trumpet 28 and laid over the roll 24 and the spool S-1 placed in winding position as shown in Figs. 3 and 4. The spool driving roll 24 is then driven to rotate the spool 8-1 to wind both the tow from the reserve container 26 and a corresponding length of the same tow from supply container 25 upon the spool S-l, forming a dye package.

The first wound spool S4, is then removed from winding position and a second winding reserve is drawn off from supply container 25 and delivered into the reserve container 26 as shown in Fig. 6, in the same manner as the first winding reserve was delivered into the reserve container 26 in Fig. 2.

Thereupon the spool on roll 24 is removed, the tow is removed from roll 24, the reserve container 26 is shifted to the entering side of the winding apparatus, and the tow from reserve container 26 and supply container 25 are doubled, inserted in the trumpet and wound upon the spool 8-2 as shown in Fig. 8.

Fig. 9 shows the dye package on spool 8-2 as completed, and it may be noted that the winding is stopped when the reserve has been removed from the reserve container 26, as in Fig. 10, and before the spool S-2 exerts any tension on the length of tow which extends between it and the previously wound spool 8-1.

The subsequent Figs. 11 through 14 represent a continuation of this procedure in the winding of a dye package upon a third spool S-3, and are believed to require no further explanation. The procedure may be continued indefinitely until all of the tow from supply container 25 has been wound onto spools.

Fig. 15 diagrammatically shows a group of four dye packages wound by this procedure with the same continuous tow T. In each of these packages the tow lies in doubled condition, since in the winding of each package a 5 pound reserve was doubled with a 5 pound length drawn from the supply container. In between the dye packages the tow extends in single condition.

It will be understood that the doubling of the tow is of particular advantage in enabling the long continuous tow to be delivered from a group of packages. This advantage is particularly applicable to those packages which are intermediate the first and last packages of the group, because even if one endmost package of the group carried its tow in a single condition, the whole continuous tow could still be satisfactorily unwound by merely starting the unwinding at the opposite end of the group. However, satisfactory unwinding of the group of packages appears to require that all of the packages intermediate the two endmost packages carry the continuous tow in doubled condition. In the preferred procedure, in which all of the packages carry the tow in doubled condition, the unwinding of the tow may be begun at either endmost package of the group.

The group of wound dye packages, prepared as explained above, may then be dyed in a suitable dye kettle, such as that of US. Patent No. 1,775,542. In this operation dye liquid is forced radially through the wound packages, dyeing the wound tow. The dye liquid is present in the kettle to a sutficient height to reach the tops of the dye packages, and consequently this liquid also dyes the portions oftow which interconnect the packages of the group.

Following dyeing, the group of packages are removed as a unit from the dye kettle and inserted as a unit in a suitable dryer for example that of US. Patent No. 2,039,285 where they are dried, following which the packages are removed as a unit from the dryer.

In subsequent treatment of the tow, the tow is withdrawn from the packages and carried away in a continuous length, in single thickness, for example as will be explained in connection with Figs. 16 to 18. In these figures, spools 8-1, 8-2 and S-3 are rotatably mounted over reserve containers 26a. The end of tow from the package of spool S1 is drawn off by nipping rolls 30 and passing downwardly through a folding device 31 into a supply container 25a. At the same time, the portion of tow which was doubled with the portion being drawn off by rolls 30 passes downward into the reserve container 26a beneath the spool 8-1.

When the spool S-1 has been exhausted, the tow from the reserve container 261: beneath the exhausted spool is then drawn by the rolls 30 as shown in Fig. 17.

When this reserve has been exhausted, the tow then is drawn from the package of spool S-2 in the same manner that tow was drawn from the package of spool 8-1, a reserve being similarly formed in the reserve container below spool 8-2, as shown in Fig. 18. This sequence of withdrawing from the package and simultaneously forming a reserve, and then withdrawing from the reserve, may be repeated until the group of packages has been exhausted and the whole length of tow drawn away in single thickness and delivered into container 25a. After the packages of spools 8-1, 8-2 and S 3 have exhausted, the next three spools of the group may be substituted and their tow similarly withdrawn. Alternatively, all the spools of the group can be left in place during the withdrawal, as in the withdrawal from spools 8-1, 5-2 and S-3. I

It will be apparent that all of the withdrawal of tow could be accomplished at the position occupied by the spool S1 and its reserve container in Fig. 16 by advancing the group of spools so that they successively occupy this position, each at the time of withdrawal of tow therefrom. In this case a reserve container would be needed only in this position.

Instead of being'folded in the supply container 25a, the single thickness tow could, if desired, pass to the next stage of treatment.

As indicated above, the large batch of continuous dyed tow produced by this procedure is suitable for economical handling by the device which converts it into top, both because of its long length and the fact that it is little disturbed in the dyeing operations.

In between the drawing off of the tow from the dye spools and the conversion to top, the dyed tow may be subjected to a heating stretching operation, in which case, after manufacture of the fabric, the fabric is heated in known manner to release the stretch and allow the fabric to relax in bulk.

While the invention is illustrated as applied to the preparation of dye packages upon perforated spools for dyeing in an Abbott dye kettle, it will be apparent that the dye packages may be wound upon removable spindles for dyeing by other systems of package dyeing.-

I claim:

1. In the preparation of tow into condition for dyeing, the preparation of a continuous length of tow in the form of a group of dye package's, inwhich at least those packages intermediate the first and last packages of the group are prepared by removing from a supply of tow a reserve length of tow and Winding this reserve length doubled with a corresponding length of the same tow into a wound package.

2. In the preparation of tow into condition for dyeing, preparing a continuous length of tow in the form of a group of dye packages by removing from a supply of tow a reserve length of tow, winding this reserve length doubled with a corresponding length of the same continuous tow into a dye package, and repeating these operations of removal and winding in the formation of the successive packages of the group, leaving the tow of each wound package continuous with that of the next wound package.

3. A length of tow prepared for dyeing, the tow being in the form of a group of wound packages and extending in continuous condition through the group of packages, at least those packages intermediate the first and last packages of the group holding the continuous tow in doubled condition.

4. A length of tow prepared for dyeing, the tow being 6 in the form of a group of wound packages and extending in continuous condition through the gr'oup of packages, at least those packages intermediate thefirst and last packages of the group holding the continuous tovv in doubled condition and the tow extending between successive packages of the group in single condition.

5. Process of dyeing tow comprising placing in a con: tainer a length of tow in the form of a group of wound dye packages with portions of the tow interconnecting the packages, the said length of tow extending in continuous condition through and between the several packages and being doubled upon itself in at least those packages intermediate the first and last packages of the group, forcing dye fluid through the packages and allowing the same dye fluid to dye the portions of tow which interconnect the packages.

6. Process of dyeing tow comprising preparing a continuous length of tow in the form of a group of interconnected dye packages in which the continuous length is doubled upon itself, dyeing the group of packages and carrying the continuous length away from the packages in single thickness.

References Cited in the file of this patent UNITED STATES PATENTS 185,625 Clark Dec. 26, 1876 227,198 Atwood May 4, 1880 1,797,393 Abbott Mar. 24, 1931 2,231,092 Schenck Feb. 11, 1941 

2. IN THE PREPARATION OF TOW INTO CONDITION FOR DYEING, PREPARATION A CONTINOUS LENGTH OF TOW IN THE FORM OF A GROUP OF DYE PACKAGES BY REMOVING FROM A SUPPLY OF TOW A RESERVE LENGTH OF TOW, WINDING THIS RESERVE LENGTH DOUBLED WITH A CORRESPONDING LENGTH OF THE SAME CONTINOUS TOW INTO A DYE PACKAGE, AND REPEATING THESE OPERATION OF REMOVAL AND WINDING IN THE FORMATION OF THE SUSSESSIVE PACKAGES OF THE GROUP, LEAVING THE TOW OF EACH WOUND PACKAGE CONTINOUS WITH THAT OF THE NEXT WOUND PACKAGE. 